Integrated e-machine controller for turbomachine having thermal path for compactly packaged electronics

The present disclosure generally relates to a controller, for example, of an e-machine of a turbomachine and, more particularly, relates to an integrated e-machine controller for a turbomachine having a thermal path for compactly packaged electronics thereof.

Some turbomachines include an e-machine, such as an electric motor or generator. More specifically, some turbochargers, superchargers, or other fluid compression devices can include an electric motor that is operably coupled to the same shaft that supports a compressor wheel, turbine wheel, etc. The electric motor may drivingly rotate the shaft, for example, to assist a turbine stage of the device. In some embodiments, the e-machine may be configured as an electric generator, which converts mechanical energy of the rotating shaft into electric energy.

These devices may also include a controller that, for example, controls operation of the e-machine. More specifically, the control system may control the torque, speed, or other operating parameters of the e-machine and, as such, control operating parameters of the rotating group of the turbomachine.

However, conventional controllers of such fluid compression devices suffer from various deficiencies. These controllers can be heavy and/or bulky. Furthermore, the electronics included in the controller may generate significant heat, which can negatively affect operations. Similarly, the operating environment of the device can subject the electronics to high temperatures, vibrational loads, or other conditions that negatively affect operations. In addition, manufacture and assembly of conventional control systems can be difficult, time consuming, or otherwise inefficient.

Thus, it is desirable to provide an e-machine controller for a fluid compression device that is retained in a robust manner. It is also desirable to provide a compact controller that operates at high efficiency. It is also desirable to provide a controller that provides a highly effective cooling effect. It is also desirable to provide improvements that increase manufacturing efficiency for such a controller. Other desirable features and characteristics of the present disclosure will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and this background discussion.

In one embodiment, a controller for an e-machine of a turbomachine is disclosed. The controller includes a coolant core with a first seat and a second seat thereon. The controller includes a semiconductor circuit component that is seated on the first seat and that is thermally coupled to the coolant core to be cooled thereby. The controller also includes a bus bar that is seated on the second seat and that is thermally coupled to the coolant core to be cooled thereby. The bus bar is thermally coupled to the semiconductor circuit component to receive heat from the semiconductor circuit component and to define a thermal path from the semiconductor circuit component, through the bus bar, and to the coolant core.

Additionally, a method of manufacturing a controller for an e-machine of a turbomachine is disclosed. The method includes providing a coolant core that has a first seat and a second seat thereon. The method also includes seating a semiconductor circuit component on the first seat including thermally coupling the semiconductor circuit component to the coolant core to be cooled thereby. Furthermore, the method includes seating a bus bar on the second seat including thermally coupling the bus bar to the coolant core to be cooled thereby. Additionally, the method includes thermally coupling the bus bar to the semiconductor circuit component to define a thermal path for heat transfer from the semiconductor circuit component, through the bus bar, and to the coolant core

In another embodiment, a compressor device is disclosed according to example embodiments. The compressor device includes a compressor section and a motor configured to drive a compressor wheel of the compressor section in rotation about an axis. Furthermore, the compressor device includes an integrated controller for the motor that includes a coolant core that extends about the axis and that includes a first seat and a second seat. The first seat is included on an outer radial area of the coolant core facing outward radially from the axis. The second seat is included on an axial end of the coolant core. The coolant core includes an internal fluid passage configured to receive a flow of a coolant. Moreover, the controller includes a semiconductor circuit component that is seated on the first seat and that is thermally coupled to the coolant core to be cooled thereby. The controller also includes a bus bar that extends about the axis, that is seated on the second seat, and that is thermally coupled to the coolant core to be cooled thereby. The bus bar is thermally coupled to the semiconductor circuit component to receive heat from the semiconductor circuit component and to define a thermal path from the semiconductor circuit component, through the bus bar, and to the coolant core

The following detailed description is merely exemplary in nature and is not intended to limit the present disclosure or the application and uses of the present disclosure. Furthermore, there is no intention to be bound by any theory presented in the preceding background or the following detailed description.

Broadly, example embodiments disclosed herein include an improved controller for a turbomachine. The controller may be integrated into, packaged among, and compactly arranged on the turbomachine for improved performance and for reducing the size and profile of the turbomachine. In some embodiments, the integrated controller may wrap, extend, span circumferentially, or otherwise be arranged about an axis of rotation defined by the rotating group of the turbomachine. The housing of the controller may be generally arcuate in some embodiments, and internal components (e.g., support structures, electronics components, and/or coolant system features) may be shaped, configured, assembled, and arranged about the axis to reduce the size of the turbomachine.

In addition, the turbomachine may be a compressor device, and the integrated controller may be arranged proximate the compressor section (e.g., proximate a compressor housing). Furthermore, the turbomachine may include a turbine section, and the compressor device may be disposed proximate thereto (e.g., proximate the turbine housing). The controller may, in some embodiments, be arranged compactly between a compressor section and a turbine section of the turbomachine. Furthermore, in some embodiments, the integrated controller may be wrapped or disposed about an e-machine (e.g., a motor) of the turbomachine. The controller may be configured for controlling the e-machine and their close proximity may increase operating efficiency. The controller may, thus, be closely integrated and packaged within the turbomachine. The components may be securely and robustly supported within the integrated controller.

The integrated controller may also include a number of electronics components for controlling operations of the e-machine. These electronics components may include one or more semiconductor circuit components, capacitors, inverters, bus bars, circuit boards, switch components, MOSFET transistors, etc.

The integrated controller may also include a number of features for cooling the electronics components of the integrated controller and/or for cooling surrounding components of the turbomachine. For example, the integrated controller may include a coolant core, which receives a flow of coolant for removing heat from the electronics components and/or other components. The coolant core may include one or more mounts, seats, attachment areas, etc. that may be used to support electronics components, and the resulting interface may increase the cooling effect. Thus, the electronics components may be tightly packed, and the turbomachine may operate at extreme conditions, yet the cooling features may maintain temperatures within an acceptable range.

Furthermore, components can be arranged compactly together within the integrated controller and, yet, may be packaged in a thermally efficient manner. For example, electronics components may be arranged in close proximity and/or may abut so as to be thermally coupled. Accordingly, a thermal path may be defined from one component and to the other. In some embodiments, one electronics component may be configured as a heat sink to another. Furthermore, in some embodiments, one electronics component may provide a thermal path from one electronics component to a coolant core of a fluid coolant system of the integrated controller.

In some embodiments, the integrated controller may include at least one semiconductor circuit components, such as a transistor module (e.g., MOSFET transistor). The semiconductor circuit component may include switches (switch elements) and leads/terminals, and the semiconductor circuit component may be supported on a fluid-cooled support structure (e.g., cold plate, coolant core, etc.) of the controller. Thus, the semiconductor circuit component may be partially cooled by the fluid-cooled support structure. Additional cooling of the semiconductor circuit component may be provided via a thermal path through another electrical component. For example, the integrated controller may include at least one bus bar that is supported on the fluid-cooled support structure, proximate the semiconductor circuit component. The bus bar may be electrically connected to the power leads/terminals of the semiconductor circuit component. This may also establish a thermal connection, wherein heat generated by the semiconductor circuit component may be transferred from the semiconductor circuit component to the bus bar, and the bus bar may, in-turn, be cooled by the fluid-cooled support structure. The bus bar may have a relatively large surface area contact with the coolant core, especially as compared with that of the semiconductor circuit component.

Accordingly, there may be high cooling effectiveness and increased operating efficiency of the controller overall. The integrated controller may operate efficiently and within acceptable operating temperatures across a wide range of operating conditions. The electronic components may be tightly packed and may operate within extreme conditions, yet the controller may maintain operations over a long operating lifetime. Additionally, features of the present disclosure may provide increases in manufacturing efficiency.

is a schematic view of an example turbomachine, such as a turbochargerthat is incorporated within an engine systemand that includes one or more features of the present disclosure. It will be appreciated that the turbochargercould be another turbomachine (e.g., a supercharger, a turbine-less compressor device, etc.) in additional embodiments of the present disclosure. Furthermore, the turbomachine of the present disclosure may be incorporated into a number of systems other than an engine system without departing from the scope of the present disclosure. For example, the turbomachine of the present disclosure may be incorporated within a fuel cell system for compressing air that is fed to a fuel cell stack, or the turbomachine may be incorporated within another system without departing from the scope of the present disclosure.

Generally, the turbochargermay include a housingand a rotating group, which is supported within the housingfor rotation about an axisby a bearing system. The bearing systemmay be of any suitable type, such as a roller-element bearing or an air bearing system.

As shown in the illustrated embodiment, the housingmay include a turbine housing, a compressor housing, and an intermediate housing. The intermediate housingmay be disposed axially between the turbine and compressor housings,.

Additionally, the rotating groupmay include a turbine wheel, a compressor wheel, and a shaft. The turbine wheelis located substantially within the turbine housing. The compressor wheelis located substantially within the compressor housing. The shaftextends along the axis of rotation, through the intermediate housing, to connect the turbine wheelto the compressor wheel. Accordingly, the turbine wheeland the compressor wheelmay rotate together as a unit about the axis.

The turbine housingand the turbine wheelcooperate to form a turbine stage (i.e., turbine section) configured to circumferentially receive a high-pressure and high-temperature exhaust gas streamfrom an engine, specifically, from an exhaust manifoldof an internal combustion engine. The turbine wheeland, thus, the other components of the rotating groupare driven in rotation around the axisby the high-pressure and high-temperature exhaust gas stream, which becomes a lower-pressure and lower-temperature exhaust gas streamthat is released into a downstream exhaust pipe.

The compressor housingand compressor wheelcooperate to form a compressor stage (i.e., compressor section). The compressor wheel, being driven in rotation by the exhaust-gas driven turbine wheel, is configured to compress received input air(e.g., ambient air, or already-pressurized air from a previous-stage in a multi-stage compressor) into a pressurized airstreamthat is ejected circumferentially from the compressor housing. The compressor housingmay have a shape (e.g., a volute shape or otherwise) configured to direct and pressurize the air blown from the compressor wheel. Due to the compression process, the pressurized air stream is characterized by an increased temperature, over that of the input air.

The pressurized airstreammay be channeled through an air cooler(i.e., intercooler), such as a convectively cooled charge air cooler. The air coolermay be configured to dissipate heat from the pressurized airstream, increasing its density. The resulting cooled and pressurized output air streamis channeled into an intake manifoldof the internal combustion engine, or alternatively, into a subsequent-stage, in-series compressor.

Furthermore, the turbochargermay include an e-machine stage. The e-machine stagemay be cooperatively defined by the intermediate housingand by an e-machinehoused therein. The shaftmay extend through the e-machine stage, and the e-machinemay be operably coupled thereto. The e-machinemay be an electric motor, an electric generator, or a combination of both. Thus, the e-machinemay be configured as a motor to convert electrical energy to mechanical (rotational) energy of the shaftfor driving the rotating group. Furthermore, the e-machinemay be configured as a generator to convert mechanical energy of the shaftto electrical energy that is stored in a battery, etc. As stated, the e-machinemay be configured as a combination motor/generator, and the e-machinemay be configured to switch functionality between motor and generator modes in some embodiments as well.

For purposes of discussion, the e-machinewill be referred to as a motor. The motormay include a rotor member (e.g., a plurality of permanent magnets) that are supported on the shaftso as to rotate with the rotating group. The motormay also include a stator member (e.g., a plurality of windings, etc.) that is housed and supported within the intermediate housing. In some embodiments, the motormay be disposed axially between a first bearingand a second bearingof the bearing system. Also, the motormay be housed by a motor housingof the intermediate housing. The motor housingmay be a thin-walled or shell-like housing that encases the stator member of the motor. The motor housingmay also encircle the axis, and the shaftmay extend therethrough.

Furthermore, the turbochargermay include an integrated controller. The integrated controllermay generally include a controller housingand a number of internal components(e.g., circuitry, electronic components, cooling components, support structures, etc.) housed within the controller housing. The integrated controllermay control various functions. For example, the integrated controllermay control the motorto thereby control certain parameters (torque, angular speed, START/STOP, acceleration, etc.) of the rotating group. The integrated controllermay also be in communication with a battery, an electrical control unit (ECU), or other components of the respective vehicle in some embodiments. More specifically, the integrated controllermay receive DC power from a vehicle battery, and the integrated controllermay convert the power to AC power for controlling the motor. In additional embodiments wherein the e-machineis a combination motor/generator, the integrated controllermay operate to switch the e-machinebetween its motor and generator functionality.

In some embodiments, the integrated controllermay be disposed axially between the compressor stage and the turbine stage of the turbochargerwith respect to the axis. The controllermay also be disposed axially between the first and second bearings,. Thus, as illustrated, the integrated controllermay be disposed and may be integrated proximate the motor. For example, as shown in the illustrated embodiment, the integrated controllermay be disposed on and may be arranged radially over the motor housing. More specifically, the integrated controllermay extend and wrap about the axisto cover over the motorsuch that the motoris disposed radially between the shaftand the integrated controller. The integrated controllermay also extend about the axisin the circumferential direction and may cover over, overlap, and wrap over at least part of the motor housing. In some embodiments, the integrated controllermay wrap between approximately forty-five degrees (45°) and three-hundred-sixty-five degrees (365°) about the axis. For example, as shown in, the controllermay wrap approximately one-hundred-eighty degrees (180°) about the axis.

shows the controller housingaccording to various example embodiments of the present disclosure. As illustrated, the housingmay generally be arcuate (e.g., crescent-shaped) so as to extend about the axisand to conform generally to the rounded profile of the turbocharger. The housingmay also be an outer shell-like member that is hollow and that encapsulates the internal components. In some embodiments, the housingmay be cooperatively defined by an outer housing bodyand a coverthat covers over an open end of the outer housing body. The housingmay attach to the motor housing, for example on an inner radial area and/or on an axial face thereof. Electrical connectorsmay extend through the housingfor electrically connecting the internal componentsto external systems. Furthermore, there may be openings for fluid couplings (e.g., couplings for fluid coolant). In some embodiments, there may be electrical connectors and fluid couplings that extend along a common direction (e.g., a single direction along the axis) to facilitate assembly of the turbocharger. Additionally, the controller housingmay define part of the exterior of the turbocharger. An outer surfaceof the controller housingmay extend about the axisand may face radially away from the axis. At least part of the outer surfacemay be smoothly contoured about the axis, and at least part of the outer surfacemay include one or more flat panels that are disposed tangentially with respect to the axisat different angular positions. The outer surfacemay be disposed generally at the same radius as the neighboring compressor housingand/or turbine housingas shown in. Accordingly, the overall size and profile of the turbocharger, including the controller, may be very compact.

The internal componentsof the controllermay be housed within the controller housing. Also, at least some of the internal componentsmay extend arcuately, wrap about, and/or may be arranged about the axisas will be discussed. Furthermore, as will be discussed, the internal componentsmay be stacked axially along the axisin close proximity such that the controlleris very compact. As such, the integrated controllermay be compactly arranged and integrated with the turbine stage, the compressor stage, and/or other components of the turbocharger. Also, internal componentsof the controllermay be in close proximity to the motorto provide certain advantages. For example, because of this close proximity, there may be reduced noise, less inductance, etc. for more efficient control of the motor.

In addition to electronics components for electronic control of the motor, the controllermay include a number of componentsthat provide robust support. The controllermay also include components that provide efficient cooling. Thus, the turbochargermay operate at extreme conditions due to elevated temperatures, mechanical loads, electrical loads, etc. Regardless, the controllermay be tightly integrated into the turbochargerwithout compromising performance.

As shown in, the internal componentsof the integrated controllermay include a coolant core. The coolant coreis shown in isolation infor clarity. As will be discussed, the coolant coremay be configured for supporting a number of electronics components, fastening structures, and other parts of the integrated controller. As such, the coolant coremay be referred to as a “support structure.” The coolant coremay be fluidly-cooled, and as such, the coolant coremay be referred to as a “cooling plate, etc.” The coolant coremay define one or more coolant passages through which a fluid coolant flows. As such, the coolant coremay receive a flow of a coolant therethrough for cooling the integrated controller.

The coolant coremay be elongate but curved and arcuate in shape and may extend in a tangential and/or circumferential direction about the axis. In other words, the coolant coremay wrap at least partially about the axisto fit about the motorof the turbocharger. Accordingly, the coolant coremay define an inner radial areathat faces the axisand an outer radial areathat faces away from the axis. Moreover, the coolant coremay include a first axial endand a second axial end, which face away in opposite axial directions. The first axial endmay face the compressor section of the turbochargerin some embodiments and the second axial endmay face the turbine section in some embodiments. The coolant coremay also define an axial width, which may be defined parallel to the axisbetween the first and second axial ends,. Additionally, the coolant coremay be semi-circular and elongate so as to extend circumferentially between a first angular endand a second angular end, which are spaced apart angularly about the axis (e.g., approximately one-hundred-eighty degrees (180°) apart).

As shown in, the coolant coremay be cooperatively defined by a plurality of parts, such as a reservoir bodyand a cover plate. Both the reservoir bodyand the cover platemay be made from strong and lightweight material with relatively high thermal conductivity characteristics (e.g., a metal, such as aluminum). In some embodiments, the reservoir bodyand/or the cover platemay be formed via a casting process (e.g., high pressure die casting).

The cover platemay be relatively flat, may be arcuate (e.g., semi-circular), and may lie substantially normal to the axis. Also, the cover platemay define the first axial endof the coolant core. The reservoir bodymay be a generally thin-walled and hollow body with an open sidethat is covered over by the cover plateand a second sidethat defines the second axial endof the coolant core. The cover platemay be fixed to the reservoir bodyand sealed thereto with a gasket, seal, etc. One or more fasteners (e.g., bolts or other fasteners may extend axially through the cover plateand the reservoir bodyfor attaching the same. The cover plateand the reservoir bodymay include one or more fastener holesthat receive a bolt or other fastener for attaching the first side electronics to the coolant core. Accordingly, the cover plateand the reservoir bodymay cooperate to define a fluid passagethat extends through the coolant core. In some embodiments, the fluid passagemay be elongate and may extend generally about the axisfrom the first angular endto the second angular end.

The coolant coremay also include at least one fluid inletto the fluid passageand at least one fluid outletfrom the fluid passage. In some embodiments, for example, there may be a single, solitary inlet. The inletmay be disposed proximate the first angular endand may include a round, cylindrical, and hollow connectorthat projects along the axisfrom the cover plateaway from the first axial end. Also, in some embodiments, there may be a single, solitary outlet. The outletmay be disposed proximate the second angular endand may include a round, cylindrical, and hollow connectorthat projects along the axisfrom the cover plateaway from the first axial end.

The coolant coremay be fluidly connected to a coolant circuit, which is illustrated schematically in. The coolant circuitmay circulate any suitable fluid, such as a liquid coolant, between the fluid passageand a heat exchanger(). More specifically, coolant may flow from the inlet, through the fluid passage, to the outlet, thereby removing heat from the integrated controller, and may continue to flow through the heat exchangerto be cooled before flowing back to the inletof the coolant core, and so on. Furthermore, as shown in, the heat exchangermay, in some embodiments, be separate and fluidly independent of an engine coolant systemthat cools the engine.

As shown in, the second axial endof the coolant coremay include one or more inner apertures. The inner aperturesmay include a plurality of pockets, recesses, receptacles, etc. that are open at the second sideof the reservoir bodyand that are disposed proximate the inner radial areaof the corein the radial direction. As shown, the inner aperturesmay be generally cylindrical in some embodiments with circular profiles and with the longitudinal axis thereof arranged parallel to the axis. There may be a plurality of inner aperturesarranged at different angular positions with respect to the axisalong the inner radial areaof the core. The size and shape of the inner aperturesmay correspond to certain ones of the internal componentsof the integrated controller. For example, the inner aperturesmay be cylindrical, as shown, to receive and support inner electronics components, such as a series of capacitors() of the controller. Furthermore, as shown in, the reservoir bodymay define the apertureswith relatively thin wallsor other structures that separate the capacitorswithin the aperturesfrom the coolant within the fluid passage. Accordingly, the capacitorsmay be effectively cooled by the coolant circuit.

Likewise, as shown in, the second sideof the reservoir bodymay include a second side aperturethat has an ovate profile and that is recessed in the axial direction into the reservoir body. The second side aperturemay be arranged with the major axis of its ovate shape extending tangentially with respect to the axis. Also, the minor axis may extend radially and may be large enough to extend over both the inner radial areaand the outer radial areaof the coolant core. Furthermore, the second side aperturemay be shaped correspondingly to another electronics component, such as an inverter, capacitor, a battery, or another piece of control equipment.

Additionally, the outer radial areaof the coolant coremay extend about the axisand may include one or more outer seats. The seatsmay be rectangular and may lie in a respective tangential plane with respect to the axis. The seatsmay be disposed and spaced apart circumferentially at different angular positions with respect to the axis. Furthermore, seatsmay include a respective outer apertureextending radially through to the interior of the core. In some embodiments, at least one outer aperturemay be a rectangular hole that is centered within the respective seatand that passes through the reservoir bodyto the fluid passagetherein. The seatmay include the rectangular rim of the respective aperture.

These outer aperturesmay be sized and configured to receive an outer electronics component(). This componentmay be and/or may include a semiconductor circuit component, such as a substantially-flat and rectangular transistor. The transistormay be a circuit component, switch component, MOSFET transistor, or another type. As shown in, the transistormay include a central portion, which may include a plurality of embedded switches and/or other electrical elements. The transistormay also include a plurality of leads. The leadsmay be flat, thin, and rectangular, and the leadsmay each project from a respective side of the central portion. In some embodiments, the leadsmay extend and project in an axial direction along the axis(e.g., substantially within a plane common with the central portion).

The transistormay be seated on a respective one of the seats. The transistormay be partially received in one of the aperturesand may be supported and mounted on a respective seatso as to cover over the respective outer aperture. There may be a gasket or other sealing member that seals the transistorto the seat. Also, the transistormay include one or more thermally-conductive projections(), such as an array of fins, rails, posts, pins, etc.) that project from an underside thereof to extend into the fluid passage. Accordingly, coolant within the coolant circuitmay flow across the projectionsto provide highly effective cooling to the transistor.

As shown in, the integrated controllermay include a fastener arrangementused for attaching at least one of the transistorsto the coolant core. The fastener arrangementmay include at least one resilient clip. The fastener arrangementmay also include fastenersused to attach respective clipsto the coolant core. Also, in some embodiments, the fastener arrangementmay include a plurality of clipsand fastenersfor retaining a plurality of the transistorson the core(e.g., on the outer radial areaof the core).

The coolant coremay include features of the fastener arrangementas well. As shown in, the coolant coremay include mountsfor the retainer clips. The mountsmay be flat areas on the outer radial areathat project outward radially. The mountsmay include a clip mounting holethat may be threaded. Also, the mountsmay include one or more (e.g., a pair) of postsor other small radial projections. The postsmay be disposed on opposite axial sides of the respective hole.

The fastener arrangementmay further include the plurality of fasteners. The fastenersmay include threaded bolts in some embodiments, which are configured to be received within respective ones of the holesto conveniently and efficiently install the transistorsto the coolant core.

The first axial endof the core(defined substantially by the cover plate) may provide a seat(i.e., a second seat) for mounting and supporting a first side electronics packageof the controller. The seatmay include one or more axially-facing surfaces of the first axial end. The seatmay be planar and/or may include a plurality of co-planar surfaces that are spaced apart across the first axial end. The seatmay include one or more surfaces on the endthat are arranged and/or that extend about the axis.

The first side electronics packageis represented schematically inas a semi-circular body that corresponds generally to the shape of the coolant core. One or more parts of the first side electronics packagemay be arcuate, may be elongate but extend about the axis, or may otherwise extend about the axis. It will be appreciated that the first side electronics packagemay comprise a plurality of electronics components, such as one or more conductive bus bars, circuit board assemblies, etc.

shows a portion of the first side electronics packageaccording to some embodiments. As shown, the first side electronics packagemay include at least one bus bar. The bus barmay be elongate and may extend about the axis. The bus barmay include a first side, a second side, an inner radial edge, and an outer radial edge. The inner and outer radial edges,may have a number of straight segments that are joined end-to-end so as to extend about the axis.

The bus barof the first side electronics packagemay be layered on the seatof the first axial endof the coolant core. In some embodiments, there may be at least one additional bus bar that is layered atop the first sideof the bus barand stacked in the axial direction. The first side electronics packagemay also include an arcuate circuit board assembly, an arcuate stiffening plate, fasteners, and/or other components arranged about the axis, and at least some of these components may be similarly stacked atop the first sideof the bus bar. The bus barand/or other components of the first side electronics packagemay be attached to the first axial endof the corein any suitable fashion, such as fasteners. Accordingly, the first side electronics packagemay be in close proximity with the coolant coresuch that the coolant coremay absorb heat therefrom with high efficiency and effectiveness. In particular, a relatively large surface area of the second sideof the bus barmay be layered upon and may abut against the seatof the coolant corefor highly effective cooling.

Also, the bus barmay include a plurality of projecting electrical terminals. At least one of the terminalsmay be flat, thin, and rectangular. There may be a plurality of terminals, which may be bent rectangular projections that extend and project axially, away from the first side. The terminalsmay be positioned to connect electrically and/or thermally with the leadsof the transistor. For example, the leadsmay overlay and abut respective ones of the terminals. There may be at least one power connection established, and as will be discussed, this may also provide a thermal path for heat to transfer from the transistor, to the bus bar, and then to the coolant core.

As represented in, the second axial endof the coolant coremay provide a seat(i.e., a third seat) for mounting and supporting a second side electronics packageof the integrated controller. The seatmay face axially, in an opposite axial direction from the seat. The seatmay include one or more surfaces on the end(on the cover plate) that are arranged and/or that extend about the axis. As shown in, the seatmay include radially-projected fastener holesfor attaching to the package.